Method of bulking textile yarns



Mam}! 1969 1.. w. SAYERS 3,430,314

METHOD OF BULKING TEXTILE YARNS Filed Sept. 29. 1965 1252s; F E??? iliilL- 4 III F/G.3 22 aim In venlor 15.74 M4 72% Jane-es A tlorncy United States Patent Ofiice 3,430,314 Patented Mar. 4, 1969 40,849/ 64 US. Cl. 2872 Int. Cl. D02j 1/08; D04b 39/00 2 Claims ABSTRACT OF THE DISCLOSURE One or more bundles of shrinkable filaments and one or more bundles of unshrinkable or less shrinkable filaments are combined by interlacing using a fiuid jet. The composite filamentary bundle obtained is incorporated in a woven or knitted fabric which is then subjected to conditions bringing about shrinkage of the shrinkable fila- This invention relates to the production of textile yarns consisting of two or more different component filaments.

In accordance with this invention textile yarns are produced by interlacing two or more bundles of at least two different types of filaments, each of the bundles having a twist in the range of to 1 turn per inch, at least one of the types of filaments having difierent potential shrinkage characteristics from the others and the interlacing being etfected without substantially increasing the net degree of twist in the filaments, and then subjecting the composite interlaced filamentary bundles to conditions producing a differential shrinkage of the filaments.

The filamentary bundles used preferably have zero twist although a small degree of twist may be present provided it does not exceed 1.0 turn per inch; thus bundles having the socalled producer twist may be used.

The interlacing of the twistless or low-twist bundles to combine them with a cohesiveness sufiicient for subsequent weaving and knitting operations may be effected by the use of air jets, for example by directing a high velocity air jet from a nozzle across the filaments into a resonance chamber as described in Canadian patent specification No. 554,150, or by the use of a texturising turbulent zone within an air jet while so controlling the tension in the filament as to prevent the formation of crunodal loops, for example as described in United States Patent No. 2,985,995.

Many types of filaments are already known which undergo shrinkage when subjected to the action of heat, and are therefore suitable for use in the present invention; other fibres which undergo shrinkage on being wetted out may also be used. Such filaments are generally those which have been stretched during their production and have not been subsequently stabilized to remove the residual shrinkage. Examples of such filaments are the polyamide filaments, for example, Nylon 6 or Nylon 66, the modacrylic filaments such as those produced from the acetone-soluble copolymers of acrylonitrile and vinylidene chloride, the acrylic filaments, polyester filaments such as polyethylene terephthalate filaments and polyolefine filaments. It is preferred that the degree of shrinkage should be of the order of 10 to 20 percent.

Examples of non-shrinkab1e filaments which can be used are cellulose acetate filaments, including both the secondary and triacetate filaments, viscose rayon filaments, including the polynosic filaments, and any of the filaments specified in the preceding paragraph which have previously been heat-stabilised to remove substantially all the residual shrinkage. Thus shrinkable nylon filaments may be interlaced with stabilized nylon filaments.

The proportion of shrinkable component in the blended interlaced product may lie in the range of 15 percent to percent by weight; I have obtained very good results using about 25 percent of shrinkable component (for example nylon) with about 75 percent of non-shrinkable component (for example a cellulose acetate type of filament).

The interlacing of bundles of filaments may be carried out by withdrawing the bundles of filaments from supply packages such as cops or cheeses and bringing them together, for example by passing them to a godet. The associated bundles are then passed from the godet t0 the interlacing jet and the interlaced compo'site yarn produced is then collected, for example on a take-up bobbin. The composite yarn may be collected with no twist being inserted or a small degre of twist of up to about 1 turn per inch may be inserted during the take-up. When one or more of the bundles of filaments contains a small degree of twist, the twist inserted is preferably of the opposite hand so that the eitect is to remove some or all of the twist in the bundles while they are in the vicinity of the interlacing jet.

The interlacing may also be carried out in conjunction with the direct production of either one of the bundles of filaments. Thus when cellulose actate filaments are used as the non-shrinking component, the filaments leaving the dry-spinning cell may be passed to a godet to which simultaneously a bundle of shrinkable filaments, for example Nylon 6 filaments, are passed over-end from a supply package. Similarly, when stretched nylon filaments are used as the shrinkable fibreh, the freshly spun and stretched filaments leaving the stretching zone may be associated with non-shrinkable filaments, for example viscose rayon or stabilised nylon filaments, withdrawn from a supply package. \Vhen shrinkable nylon filaments are to be interlaced with stabilised nylon filaments, both types may be produced directly and passed together to the interlacer.

In general, the degree of interlacing obtained with the filamentary bundles is controlled by the volume of air supplied to the interlacing jet. Air pressures of the order of 20 to 50 lb. per square inch have been used successfully to give satisfactory interlaced products.

The methods of interlacing described in the preceding paragraphs are illustrated in the accompanying drawings in which:

FIGURE 1 shows the interlacing of freshly-produced dry-spun filaments with preformed shrinking filaments,

FIGURE 2 shows the interlacing of freshly-produced melt-spun and stretched filaments with preformed nonshrinking filaments, and

FIGURE 3 shows a form of interlacer in cross-section.

In FIGURE 1, dry spun substantially straight, i.e. uncrimped, filaments 1 extruded from a jet 2 in a dry-spinning cell 3 are passed to and round a godet 4. Shrinkable substantially straight filaments 5 are simultaneously passed over-end from a supply bobbin to the godet 4 to produce an associated bundle of filaments 7 which is passed through an interlacing jet 8. The interlaced filaments are then collected by a conventional ring 9 and traveller 10 on a bobbin 11. In FIGURE 2, melt spun substantially straight filaments 12 are passed from cell 13 round a godet 14 and are then stretched while being passed to a second godet 15 having the required peripheral speed to give the desired degree of stretch. A bundle of nonshrinkable substantially straight filaments 16 are withdrawn over-end from a bobbin 17 and passed to the godet 15 to form an associated bundle of filaments 18 which is passed to an interlacing jet 19. The interlaced filaments are then collected on a tube 20 as shown using a conventional ring and traveller.

In the jet shown in FIGURE 3, the interlacer 21 has a passage 22 for the filaments and the passage has a cover plate 23 having a conduit 24 for supplying fluid to the filaments passing through the passage 22.

The shrinkage of the shrinkable component in the interlaced bundle may be carried out directly on the bundle of filaments so as to produce a bulked product suitable for use in normal textile applications for bulked yarns. Such shrinkage may conveniently be carried out with the interlaced product in the form of hanks or by a continuous in line process involving the use of a steamchamber or a heated aqueous bath. The shrinkage can usually be carried out by heating the filaments to a temperature sufficient to bring about the shrinkage or, in the case of filaments shrinking on wetting out, passing the filaments through a liquid aqueous bath or a steam chamber.

Useful filaments may be obtained by subjecting the interlaced yarns obtained according to this invention to a bulking process such as a false twist crimping process, or a texturising process as described in the Breen Patent No. 2,783,609. False twist yarns of this type may be used with advantage in knitted fabric.

Novelty filaments may also be obtained by over-feeding one bundle of filaments to the interlacing jet relatively to the other bundle so that, in addition to the interlacing effect, one of the bundles has a number of crunodal loops introduced.

It is preferred, however, to bring about the shrinkage of the shrinkable component, and the consequent increase in bulk or other special effect, after the interlaced product has been incorporated in a textile product such as a woven or knitted fabric, i.e., a structured fabric. Using the interlaced product, yarn processing such as warping and pirning can be carried out as if the product were a conventional low twist yarn, i.e. l to 5 turns per inch; allowances do not have to be made for special effects which develop only in fabric form, thereby simplifying the processing steps. For example, by using the interlaced product as a warp or weft, or as both, in a woven fabric and then shrinking the shrinkable component, a cockled or crepe effect is obtained; thus after the shrinking a simple twill weave may be made to appear as a crepe weave without the need for a twisting operation. Viscose rayon and nylon filaments may be interlaced and used in the production of a strong shirting fabric which, after shrinking, has a homogeneous appearance and is both permeable and abrasion resistant.

The interlacing treatment may be carried out so as to obtain new surface effects, for example lustre effects, using combinations of filaments of different cross-section. If desired differential colour effects may also be obtained using fibres having different dyeing properties. Similar effects may be obtained by reserving one of the components during the dyeing. The degree of interlacing along the lengths of the filaments may also be varied to obtain new effects.

The invention is illustrated by the following examples.

EXAMPLE 1 Using apparatus substantially as illustrated in FIGURE 1, a 55 denier/13 filament secondary acetate filamentary bundle was collected on the godet 4 together with a 40 denier/ filament Nylon 6 bundle (twist 0.3 turn per inch Z) from a bobbin 6. The nylon filaments shrink about percent when immersed free from tension, in boiling or near boiling water. The bundles were passed at a speed of 200 metres/minute to an interlacing jet constructed substantially as shown in FIGURE 8 of United States Patent No. 2,985,995, the conduit being 0.040 inch wide and the air pressure 40 lb./square inch. The interlaced yarn was collected on a bobbin using a ring and traveller inserting 0.6 turn per inch S. The composite interlaced yarn was found to have 10 knots per metre.

A fabric was woven using the product as weft, the details being as follows:

Weave Twill.

Warp 75/ 19 triacetate yarn twisted with 30/6 Nylon 6 yarn.

Weft Interlaced 55/13 acetate,

10 Nylon 6 yarn.

Ends per inch 96.

Picks per inch 96.

The fabric Was contracted in open width to give a contraction of 10 percent on the actual grey fabric width in near boiling water, scoured and dyed on the winch, spun dried in rope form and stentered to remove creasing and to heat-set the fabric. The product was a fabric having the appearance of crepe weave.

EXAMPLE 2 Using the procedure and conditions outlined in Example l a 75 denier/ 20 filament bundle of secondary acetate filaments was interlaced with a 40 denier/ 10 filament bundle of Nylon 6 filaments. The product had 10 knots per metre.

The interlaced product was woven into a fabric as follows:

The fabric was finished as described in Example 1 to produce a fabric having a crepe weave appearance.

The interlaced product was also false-twisted and knitted into panels and the panels were dyed in baths in which the nylon was reserved. The products were fabrics having a marl appearance.

EXAMPLE 3 In this example a bundle of denier/24 filament triacetate filaments was interlaced at 200 metres per minute with a bundle of 40 denier/10 filament Nylon 6 filaments using the jet illustrated in FIGURE 3 of the accompanying drawings, the conduit being 0.040 inch .wide and the air pressure 30 lb./ square inch. The product obtained had 40 knots per metre.

The interlaced product was woven into a fabric as follows:

Weave Twill.

Warp 100/26 secondary acetate.

Weft Interlaced 100/ 24 triacetate,

40/10 Nylon 6.

Ends per inch 108.

Picks per inch 70.

The fabric was finished as described in Example 1 to give a fabric having a crepe Weave appearance.

What I claim is 1. A process for the production of crepe textile fabric which comprises subjecting a first bundle of substantially straight filaments selected from the group consisting of cellulose acetate and viscose rayon filaments and a second bundle of substantially straight nylon filaments, said bundles having twists of 0 to 1 turn per inch and the nylon filaments having a different potential shrinkage of from 10 to 20 percent as compared with the filaments of said first bundle, to an interlacing treatment in a fluid jet to combine the bundles with a cohesiveness sufficient for weaving and knitting operations, and without inserting twist in said combined bundles, incorporating the composite interlaced product in a structured fabric and then subjecting the fabric to conditions producing a differential shrinkage of the nylon filaments in the composite interlaced bundles.

2. A process as claimed in claim 1 wherein the proportion of nylon in the interlaced product is in the range of 15 to 75 percent by weight.

References Cited UNITED STATES PATENTS 9/1959 Groornbridge et a1. 57-157 2/1962 Daniels et a1. 2872 LOUIS K. RI-MRODT, Primary Examiner. 

